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US20100301509A1 - Coating composition for foam particles, and method for the production of molded foam bodies - Google Patents

Coating composition for foam particles, and method for the production of molded foam bodies Download PDF

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Publication number
US20100301509A1
US20100301509A1 US12/677,994 US67799408A US2010301509A1 US 20100301509 A1 US20100301509 A1 US 20100301509A1 US 67799408 A US67799408 A US 67799408A US 2010301509 A1 US2010301509 A1 US 2010301509A1
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US
United States
Prior art keywords
weight
foam particles
foam
coating composition
particles
Prior art date
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Abandoned
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US12/677,994
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English (en)
Inventor
Benjamin Nehls
Klaus Hahn
Andreas Keller
Bernhard Schmied
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BASF SE
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BASF SE
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Assigned to BASF SE reassignment BASF SE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SCHMIED, BERNHARD, KELLER, ANDREAS, HAHN, KLAUS, NEHLS, BENJAMIN
Publication of US20100301509A1 publication Critical patent/US20100301509A1/en
Abandoned legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/224—Surface treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products
    • C08J9/232—Forming foamed products by sintering expandable particles
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C09D1/02—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates
    • C09D1/04—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates with organic additives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/02—Polysilicates
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/036—Use of an organic, non-polymeric compound to impregnate, bind or coat a foam, e.g. fatty acid ester
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
    • C08J2325/02—Homopolymers or copolymers of hydrocarbons
    • C08J2325/04—Homopolymers or copolymers of styrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/08—Ingredients agglomerated by treatment with a binding agent

Definitions

  • the invention relates to a coating composition, a process for producing coated foam particles and also foam moldings produced therefrom and their use.
  • Particle foams are usually obtained by sintering foam particles, for example prefoamed expandable polystyrene particles (EPS) or expanded polypropylene particles (EPP), in closed molds by means of steam.
  • EPS prefoamed expandable polystyrene particles
  • EPP expanded polypropylene particles
  • Polystyrene foams having a low flammability are generally provided with halogen-comprising flame retardants such as hexabromocyclododecane (HBCD).
  • halogen-comprising flame retardants such as hexabromocyclododecane (HBCD).
  • HBCD hexabromocyclododecane
  • their permitted use as insulation materials in the building sector is restricted to particular applications. The reason for this is, inter alia, the melting and dripping of the polymer matrix in the case of fire.
  • the halogen-comprising flame retardants are not able to be used without restriction because of their toxicological properties.
  • WO 00/050500 describes flame-resistant foams made of prefoamed polystyrene particles which are mixed with an aqueous sodium silicate solution and a latex of a high molecular weight vinyl acetate copolymer, poured into a mold and dried in air while shaking. This gives only a loose bed of polystyrene particles which are conglutinated at only a few points and therefore have only unsatisfactory mechanical strengths.
  • WO 2005/105404 describes an energy-saving process for producing foam moldings, in which the prefoamed foam particles are coated with a resin solution which has a softening temperature lower than that of the expandable polymer.
  • the coated foam particles are subsequently fused in a mold with application of external pressure or by after-expansion of the foam particles by means of hot steam.
  • WO 2005/07331 describes expanded polystyrene foam particles having a functional coating which is applied by means of a solvent which attacks the polystyrene foam particles to only a small extent.
  • the surface can, for example, be coated with a methanolic polyvinyl acetate solution comprising aluminum hydroxide particles.
  • the particles have to be sprayed with a release liquid, for example ethylene glycol.
  • WO 2007/023089 describes a process for producing foam moldings from prefoamed foam particles which have a polymer coating.
  • a mixture of a water glass solution, water glass powder and a polymer dispersion is used as preferred polymer coating.
  • hydraulic binders based on cement or metal salt hydrates, for example aluminum hydroxide can be added to the polymer coating.
  • Hydraulic binders such as cement set even at room temperature in an aqueous slurry in the presence of carbon dioxide. Embrittlement of the foam board can occur as a result.
  • the foam boards produced according to the prior art cited are not stable in the case of fire at temperatures above 800° C. and collapse in the case of fire.
  • the coating should, in particular, not lead to embrittlement of the foam moldings and ensure the structural integrity of the foam moldings even at temperatures above 800° C.
  • a preferred coating composition comprises
  • the preceding amounts relate in each case to solids based on solids of the coating composition.
  • the components a) to c) or a) to d), respectively, add up to 100% by weight.
  • the weight ratio of clay mineral to alkali metal silicate in the coating composition is preferably in the range from 1:2 to 2:1.
  • the coating composition comprises an uncrosslinked polymer which has one or more glass transition temperatures in the range from ⁇ 60° to +100° C. as film-forming polymer.
  • the glass transition temperatures of the dried polymer film are preferably in the range from ⁇ 30° to +80° C., particularly preferably in the range from ⁇ 10° to +60° C.
  • the glass transition temperature can be determined by means of differential scanning calorimetry (DSC, in accordance with ISO 11357-2, heating rate 20 K/min).
  • the molecular weight of the polymer film determined by gel permeation chromatography (GPC) is preferably below 400 000 g/mol.
  • the polymers can, if appropriate, comprise from 1 to 5% by weight of comonomers such as (meth)acrylonitrile, (meth)acrylamide, ureido (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, acrylamidopropanesulfonic acid, methylolacrylamide or the sodium salt of vinylsulfonic acid.
  • comonomers such as (meth)acrylonitrile, (meth)acrylamide, ureido (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, acrylamidopropanesulfonic acid, methylolacrylamide or the sodium salt of vinylsulfonic acid.
  • the film-forming polymer is particularly preferably made up of one or more of the monomers styrene, butadiene, acrylic acid, methacrylic acid, C 1-4 -alkyl acrylates, C 1-4 -alkyl methacrylates, acrylamide, methacrylamide and methylol acrylamide.
  • An infrared-absorbing pigment such as carbon black, coke, aluminum, graphite or titanium oxide is preferably used in amounts of from 5 to 40% by weight, in particular in amounts of from 10 to 30% by weight, based on the solid of the coating, to reduce the thermal conductivity.
  • the particle size of the IR-absorbing pigment is generally in the range from 0.1 to 100 ⁇ m, in particular in the range from 0.5 to 10 ⁇ m.
  • the BET surface area is preferably in the range from 10 to 120 m 2 /g.
  • graphite preference is given to using graphite having an average particle size in the range from 1 to 50 ⁇ m.
  • the coating composition can comprise intumescent compositions which comprise chemically bound water or eliminate water at temperatures above 40° C., e.g. metal hydroxides, metal salt hydrates and metal oxide hydrates, as additional additives.
  • Suitable metal hydroxides are, in particular, those of groups 2 (alkaline earth metals) and 13 (boron group) of the Periodic Table of the Elements. Preference is given to magnesium hydroxide, aluminum hydroxide and borax. Particular preference is given to aluminum hydroxide.
  • Preferred metal salt hydrates are the hydrates of metal halides (in particular chlorides), sulfates, carbonates, phosphates, nitrates or borates.
  • Suitable metal salt hydrates are, for example, magnesium sulfate decahydrate, sodium sulfate decahydrate, copper sulfate pentahydrate, nickel sulfate heptahydrate, cobalt(II) chloride hexahydrate, chromium(III) chloride hexahydrate, sodium carbonate decahydrate, magnesium chloride hexahydrate and the tin borate hydrates.
  • Magnesium sulfate decahydrate and tin borate hydrates are particularly preferred.
  • M I can be, for example, potassium, sodium, rubidium, cesium, ammonium, thallium or aluminum ions.
  • M III can be, for example, aluminum, gallium, indium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, rhodium or iridium.
  • cements for example cements, aluminum oxides, vermiculite or perlite
  • these can be introduced into the coating composition in the form of aqueous slurries or dispersions. Cements can also be applied to the foam particles by “dusting”. The water necessary for setting of the cement can then be introduced as steam during sintering.
  • the coating composition is used, in particular, for coating foam particles.
  • foam particles it is possible to use expanded polyolefins such as expanded polyethylene (EPE) or expanded polypropylene (EPP) or prefoamed particles of expandable styrene polymers, in particular expandable polystyrene (EPS).
  • EPE expanded polyethylene
  • EPP expanded polypropylene
  • EPS expandable polystyrene
  • the foam particles generally have an average particle diameter in the range from 2 to 10 mm.
  • the bulk density of the foam particles is generally from 5 to 100 kg/m 3 , preferably from 5 to 40 kg/m 3 and in particular from 8 to 16 kg/m 3 , determined in accordance with DIN EN ISO 60.
  • prefoamed, expandable styrene polymers which comprise athermanous solids such as carbon black, aluminum, graphite or titanium dioxide, in particular graphite having an average particle diameter in the range from 1 to 50 ⁇ m, in amounts of from 0.1 to 10% by weight, in particular from 2 to 8% by weight, based on EPS, and are known from, for example, EP-B 981 574 and EP-B 981 575.
  • the foam particles can comprise from 3 to 60% by weight, preferably from 5 to 20% by weight, based on the prefoamed foam particles, of a filler.
  • a filler Possible fillers are organic and inorganic powders or fibrous materials, and also mixtures thereof.
  • organic fillers it is possible to use, for example, wood flour, starch, flax, hemp, ramie, jute, sisal, cotton, cellulose or aramid fibers.
  • inorganic fillers it is possible to use, for example, carbonates, silicates, barite, glass spheres, zeolites or metal oxides.
  • pulverulent inorganic materials such as talc, chalk, kaolin (Al 2 (Si 2 O 5 )(OH) 4 ), aluminum hydroxide, magnesium hydroxide, aluminum nitride, aluminum silicate, barium sulfate, calcium carbonate, calcium sulfate, silica, quartz flour, Aerosil®, alumina or wollastonite or spherical or fibrous, inorganic materials such as glass spheres, glass fibers or carbon fibers.
  • inorganic fillers having a density in the range 1.0-4.0 g/cm 3 , in particular in the range 1.5-3.5 g/cm 3 .
  • the whiteness/brightness (DIN/ISO) is preferably 50-100%, in particular 60-98%.
  • the type and amount of fillers can influence the properties of the expandable thermoplastic polymers and the particle foam moldings obtainable therefrom.
  • the use of bonding agents such as styrene copolymers modified with maleic anhydride, polymers comprising epoxide groups, organosilanes or styrene copolymers having isocyanate or acid groups can significantly improve the bonding of the solid to the polymer matrix and thus the mechanical properties of the particle foam moldings.
  • inorganic fillers reduce the combustibility.
  • the burning behavior can be improved further by, in particular, addition of inorganic powders such as aluminum hydroxide, magnesium hydroxide or borax.
  • Such filler-comprising foam particles can, for example, be obtained by foaming of filler-comprising, expandable thermoplastic granules.
  • the expandable granules required for this purpose can be obtained by extrusion of thermoplastic melts comprising blowing agent and subsequent underwater pelletization under pressure, as described in, for example, WO 2005/056653.
  • the polymer foam particles can additionally be provided with further flame retardants.
  • They can for this purpose comprise, for example, from 1 to 6% by weight of an organic bromine compound such as hexabromocyclododecane (HBCD) and, if appropriate, also from 0.1 to 0.5% by weight of dicumyl or a peroxide in the interior of the foam particles or the coating.
  • HBCD hexabromocyclododecane
  • dicumyl or a peroxide in the interior of the foam particles or the coating.
  • preference is given to using no halogen-comprising flame retardants.
  • the coating composition of the invention is preferably applied in the form of an aqueous polymer dispersion together with the clay mineral and the alkali metal silicate and, if appropriate, infrared-absorbing pigments and further additives to the foam particles.
  • Suitable polymer dispersions can be obtained, for example, by free-radical emulsion polymerization of ethylenically unsaturated monomers such as styrene, acrylates or methacrylates, as described in WO 00/50480.
  • the polymer dispersion is prepared in a manner known per se, for instance by emulsion, suspension or dispersion polymerization, preferably in an aqueous phase.
  • the polymer can also be prepared by solution or bulk polymerization, broken up if appropriate and the polymer particles can subsequently be dispersed in water in a customary fashion.
  • the polymerization is carried out using the initiators, emulsifiers or suspension aids, regulators or other auxiliaries customary for the respective polymerization process and is carried out continuously or batchwise at the temperatures and pressures customary for the respective process in conventional reactors.
  • the water glass powder comprised in the coating mixture leads to improved or faster film formation from the polymer dispersion and thus to faster curing of the foam molding.
  • hydraulic binders based on cement, lime-cement or gypsum plaster can additionally be added in amounts at which no significant embrittlement of the foam occurs.
  • foam particles it is possible to use customary methods such as spraying, dipping or wetting of the foam particles with/into an aqueous polymer dispersion in customary mixers, spray apparatuses, dipping apparatuses or drum apparatuses.
  • the foam particles which have been coated according to the invention can additionally be coated with amphiphilic or hydrophobic organic compounds. Coating with hydrophobicizing agents is advantageously carried out before application of the aqueous polymer dispersion according to the invention.
  • hydrophobic organic compounds mention may be made of, in particular, C 10 -C 30 paraffin waxes, reaction products of N-methylolamine and a fatty acid derivative, reaction products of a C 9 -C 11 oxo alcohol with ethylene oxide, propylene oxide or butylene oxide or polyfluoroalkyl (meth)acrylates or mixtures thereof, which are preferably used in the form of aqueous emulsions.
  • Preferred hydrophobicizing agents are paraffin waxes which have from 10 to 30 carbon atoms in the carbon chain and preferably have a melting point in the range from 10 to 70° C., in particular from 25 to 60° C.
  • paraffin waxes are comprised, for example, in the commercial BASF products RAMASIT KGT, PERSISTOL E and PERSISTOL HP and also in AVERSIN HY-N from Henkel and CEROL ZN from Sandoz.
  • Suitable hydrophobicizing agents comprises resin-like reaction products of an N-methylolamine with a fatty acid derivative, e.g. a fatty acid amide, fatty amine or fatty alcohol, as are described, for example, in U.S. Pat. No. 2,927,090 or GB-A 475 170. Their melting point is generally in the range from 50 to 90° C.
  • resins are comprised, for example, in the commercial BASF product PERSISTOL HP and in ARCOPHOB EFM from Hoechst.
  • polyfluoroalkyl (meth)acrylates for example polyperfluorooctyl acrylate, are also suitable. This substance is comprised in the commercial BASF product PERSISTOL O and in OLEOPHOBOL C from Pfersee.
  • coating agents are antistatics such as Emulgator K30 (mixture of secondary sodium alkanesulfonates) or glyceryl stearates such as glyceryl monostearate GMS or glyceryl tristearate.
  • customary coating agents, in particular stearates can be used in reduced amounts or be dispensed with entirely for coating expandable polystyrene in the process of the invention without having an adverse effect on the product quality.
  • the foam particles provided with the coating according to the invention can be sintered in a mold.
  • the coated foam particles can still be moist or have been dried.
  • Drying of the polymer dispersion applied to the foam particles can, for example, be carried out in a fluidized bed, paddle dryer or by passing air or nitrogen through a loose bed.
  • the water content of the coated foam particles after drying is preferably in the range from 1 to 40% by weight, particularly preferably in the range from 2 to 30% by weight, very particularly preferably in the range from 5 to 15% by weight. It can be determined, for example, by Karl-Fischer titration of the coated foam particles.
  • the weight ratio of foam particles/coating mixture after drying is preferably from 2:1 to 1:10, particularly preferably from 1:1 to 1:5.
  • foam particles which have been coated according to the invention can be sintered by means of hot air or steam in customary molds to produce foam moldings.
  • the pressure can, for example, be generated by reducing the volume of the mold by means of a movable punch. In general, a pressure in the range from 0.5 to 30 kg/cm 2 is set here.
  • the mixture of coated foam particles is for this purpose introduced into the opened mold. After closing the mold, the foam particles are pressed by means of the punch, with the air between the foam particles being pushed out and the volume of the interstices being reduced.
  • the foam particles are joined by the polymer coating to form foam moldings.
  • the bed of particles is preferably compacted to about 50% of the starting volume.
  • a pressure of from 1 to 5 bar is generally sufficient for this.
  • the mold is configured according to the desired geometry of the foam body.
  • the degree of fill depends, inter alia, on the desired thickness of the future molding.
  • a simple box-like mold can be used.
  • Compaction can, for example, be achieved by shaking the mold, tumbling motions or other suitable measures.
  • hot air or steam can be injected into the mold or the mold can be heated.
  • any heat transfer media such as oil or steam can be used for heating the mold.
  • the hot air or the mold is for this purpose advantageously heated to a temperature in the range from 20 to 120° C., preferably from 30 to 90° C.
  • sintering can be carried out continuously or batchwise with injection of microwave energy.
  • Microwaves in the frequency range from 0.85 to 100 GHz, preferably from 0.9 to 10 GHz, and irradiation times in the range from 0.1 to 15 minutes are generally used here. In this way, foam boards having a thickness of more than 5 cm can also be produced.
  • the process can also be carried out without external pressure and without a reduction in the volume of the mold.
  • the internal pressure produced by the microwaves or elevated temperatures allows the foam particles to undergo slight further expansion and also fuse together as a result of softening of the foam particles themselves in addition to conglutination via the polymer coating. This results in the interstices between the foam particles disappearing.
  • the mold can also be additionally heated as described above by means of a heat transfer medium.
  • double belt units as are used for producing polyurethane foams are also suitable.
  • the prefoamed and coated foam particles can be applied continuously to the lowermost of two metal belts, which may have perforations if appropriate, and processed with or without compression due to the metal belts coming together to produce continuous foam boards.
  • the volume between the two belts is increasingly reduced so that the product between the belts is compressed and the interstices between the foam particles disppear. After a curing zone, a continuous board is obtained.
  • the volume between the belts can be kept constant and the belts can run through a zone into which hot air or microwaves are introduced and in which the foam particles foam further. Here too, the interstices disappear and a continuous board is obtained. It is also possible to combine the two continuous embodiments of the process.
  • the thickness, length and width of the foam boards can vary within wide limits and are limited by the size and closure force of the tool.
  • the thickness of the foam boards is usually from 1 to 500 mm, preferably from 10 to 300 mm.
  • the density of the foam moldings in accordance with DIN 53420 is generally from 10 to 150 kg/m 3 , preferably from 20 to 90 kg/m 3 .
  • the process makes it possible to obtain foam moldings having a uniform density over the entire cross section.
  • the density of the outer layers corresponds approximately to the density of the inner regions of the foam molding.
  • Comminuted foam particles obtained from recycled foam moldings can also be used in the process. It is possible for the foam moldings of the invention to be produced using 100% comminuted recycled foam or proportions of, for example, from 2 to 90% by weight, in particular from 5 to 25% by weight, of comminuted recycled foam together with fresh product without significantly impairing the strength and the mechanical properties.
  • a preferred process comprises the steps:
  • the process is suitable for producing simple or complex foam moldings such as boards, blocks, tubes, rods, profiles, etc. Preference is given to producing boards or blocks which can subsequently be sawn or cut to produce boards. They can be used, for example, in building and construction for the insulation of exterior walls. They are particularly preferably used as core layer for producing sandwich elements, for example structural insulation panels (SIPs) which are used for the construction of coolstores or warehouses.
  • SIPs structural insulation panels
  • the clay minerals used according to the invention can easily be dispersed in aqueous polymer dispersions and applied to the prefoamed foam particles. Ceramization by means of the alkali metal silicate occurs only in the case of fire at temperatures above about 500° C.
  • the use of clay minerals such as kaolin in the coating composition does not lead to embrittlement of the foam molding during sintering.
  • the porous ceramic framework structure formed in the case of fire subsequently withstands temperatures above 1000° C.
  • the foam particles provided with the coating according to the invention can be sintered to form foam moldings which have a high fire resistance value E30, in particular E60, or F30, in particular F60, and even on prolonged application of flames for over 30 or 60 minutes prevent passage of flames, with the structural integrity being maintained by the porous ceramic framework structure formed.
  • sealing strips are generally used in the joins between the individual sandwich elements (panels).
  • the seal should be designed so that the join facing away from the source of heat remains gastight even when the panels are subjected in the case of fire, i.e. under the action of heat, to dimensional changes which in the region of the joins can lead to stresses and consequently movements in different directions in space.
  • Sealing strips of polyurethanes generally become brittle at about 120° C. If the sealing strip is exposed to hot vapors it becomes brittle and thus loses its sealing properties. The hot gases therefore penetrate through the join and the temperature sensors on the outside are heated as a result.
  • the sealing strips should not only remain elastic under the action of heat but also be able to “expand further” within certain limits, i.e. have intumescent properties, in order to maintain gastightness in the case of dimensional changes in the region of the join, in particular in the event of cracks being formed. Preference is therefore given to using intumescent sealing strips between the abutting core layers of the sandwich elements, which strips then foam stepwise as the join widens and thus retard the spread of heat and of gas. This measure allows the temperature stress acting on the join facing away from the source of heat to be reduced and the survival time of the “outer join” to be improved significantly.
  • Foam-like structures or elastic fiber structures which are laid into the joins during construction of the panels and are compressed on final fixing of the panels to the substrate construction are also conceivable.
  • this elastic “inlay” can adapt to the altered dimensions in the region of the join and thereby seal it more efficiently.
  • Materials suitable for this purpose are, for example, melamine resin foams (Basotect® from BASF SE), mineral wool strips or a flame-retardant polyethylene foam strip.
  • Suitable materials for the tongue are, for example, regips strips, strips made of silicone or intumescent materials such as expandable graphite or silicates, for example Palusol® or the coating composition according to the invention, mineral fiber wedges, wedges made of melamine resin foams (Basotect®), thin metal strips which can be introduced on each side into a thin groove.
  • Polystyrene foam particles (density: 10 g/l)
  • the polystyrene foam particles were homogeneously coated with a coating mixture comprising the composition reported in proportions by weight in table 1 in a weight ratio of 1:4 in a mixer.
  • the coated polystyrene foam particles were introduced into an aluminum mold (20 cm ⁇ 20 cm) and compressed under pressure to 50% of the original volume.
  • the molding was taken from the mold and the thermal conductivity was determined at 20° C. in an ANACON two-plate measuring instrument using a method based on DIN 52612.
  • the volume reduction was determined as a measure of the stability of the ceramized structure after storage at 1050° C. for 5 minutes in a crucible furnace.
  • the coated polystyrene foam particles were introduced into an aluminum mold (20 cm ⁇ 20 cm) and compressed under pressure to 50% of the original volume at 70° C. for 60 minutes.
  • the molding was taken from the mold and the thermal conductivity was measured at 20° C. in an ANACON two-plate measuring instrument.
  • the volume reduction after storage at 1050° C. for 5 minutes in a crucible furnace was determined.
  • the specimens from comparative experiments 3a to 3j display very poor matrix stability when they come into direct contact with a flame.
  • the volume reduction after storage at 1050° C. for 5 minutes in a crucible furnace was in all cases above 75%.

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US20120032103A1 (en) * 2010-08-09 2012-02-09 Basf Se High-temperature-stable and moisture-stable materials which have improved insulation properties and are based on foams and disperse silicates
US20120301700A1 (en) * 2011-05-27 2012-11-29 Sto Ag Method for manufacturing a formed body with a cavity structure for sound and/or heat insulation and formed body for sound and/or heat insulation
US20160297944A1 (en) * 2013-11-13 2016-10-13 Sto Se & Co. Kgaa Process for producing an insulation and drainage sheet and insulation and drainage sheet
EP2623288B1 (de) * 2012-02-06 2019-07-17 BEWiSynbra RAW B.V. Verfahren zur Herstellung geschäumter Formteile
US10662309B2 (en) 2015-05-19 2020-05-26 Basf Se Article comprising tubular particles
WO2022117331A1 (en) * 2020-12-02 2022-06-09 Evonik Operations Gmbh Adhesion of blowing agent-containing particles based on polyimides or polyacrylates
US20220267565A1 (en) * 2019-07-05 2022-08-25 First Point a.s. Insulation Material and a Method for its Production
FR3123360A1 (fr) * 2021-05-31 2022-12-02 Neolido Technology Sa Composition ignifugeante et ses utilisations
WO2024243729A1 (en) * 2023-05-26 2024-12-05 Sika Technology Ag Intumescent composition

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WO2010146146A1 (de) * 2009-06-19 2010-12-23 Basf Se Beschichtete schaumstoffpartikel
WO2011064230A1 (de) 2009-11-27 2011-06-03 Basf Se Beschichtungszusammensetzung für schaumstoffpartikel
WO2012019988A1 (de) 2010-08-09 2012-02-16 Basf Se Hochtemperatur- und feuchtigkeitsstabile werkstoffe mit verbesserten isolationseigenschaften auf basis von schaumstoffen und dispersen silikaten
DE102010053611A1 (de) * 2010-12-07 2012-06-14 Sto Ag Wärmedämmplatte, Verfahren zur Herstellung einer Wärmedämmplatte
CN103073804A (zh) * 2012-12-14 2013-05-01 刘开森 一种防火保温板的制备方法
RU2595676C2 (ru) * 2014-11-13 2016-08-27 Общество с ограниченной ответственностью "Природоохранные технологии" Самозатухающий пенополистирол
CN105753483B (zh) * 2014-12-17 2018-05-15 尹嘉权 一种散热器陶瓷材料
PL3268421T3 (pl) * 2015-03-13 2021-02-22 Basf Se Przewodzące prąd elektryczny tworzywa piankowe z cząstek na bazie termoplastycznych elastomerów
JP7760510B2 (ja) * 2020-01-31 2025-10-27 ダウ グローバル テクノロジーズ エルエルシー コーティングされたポリウレタン発泡体

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US5786095A (en) * 1996-07-03 1998-07-28 H.B. Fuller Licensing & Financing, Inc. Inorganic based intumescent system
US6130265A (en) * 1997-05-14 2000-10-10 Basf Aktiengesellschaft Method for producing expandable styrene polymers containing graphite particles
US6340713B1 (en) * 1997-05-14 2002-01-22 Basf Aktiengesellschaft Expandable styrene polymers containing graphite particles
US6727327B1 (en) * 1999-02-25 2004-04-27 Basf Aktiengesellschaft Aqueous n-butyl acrylate copolymer dispersions for use as laminating adhesives
US20070112082A1 (en) * 2003-12-12 2007-05-17 Basf Aktiengesellschaft Moldable-foam moldings composed of expandable pelletized filled polymer materials
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US20120032103A1 (en) * 2010-08-09 2012-02-09 Basf Se High-temperature-stable and moisture-stable materials which have improved insulation properties and are based on foams and disperse silicates
US20120301700A1 (en) * 2011-05-27 2012-11-29 Sto Ag Method for manufacturing a formed body with a cavity structure for sound and/or heat insulation and formed body for sound and/or heat insulation
US20140127436A1 (en) * 2011-05-27 2014-05-08 Sto Ag Method for manufacturing a formed body with a cavity structure for sound and/or heat insulation and formed body for sound and/or heat insulation
US8784709B2 (en) * 2011-05-27 2014-07-22 Sto Se & Co. Kgaa Method for manufacturing a formed body with a cavity structure for sound and/or heat insulation and formed body for sound and/or heat insulation
EP2623288B1 (de) * 2012-02-06 2019-07-17 BEWiSynbra RAW B.V. Verfahren zur Herstellung geschäumter Formteile
US20160297944A1 (en) * 2013-11-13 2016-10-13 Sto Se & Co. Kgaa Process for producing an insulation and drainage sheet and insulation and drainage sheet
US10662309B2 (en) 2015-05-19 2020-05-26 Basf Se Article comprising tubular particles
US10829608B2 (en) 2015-05-19 2020-11-10 Basf Se Article comprising tubular particles
US20220267565A1 (en) * 2019-07-05 2022-08-25 First Point a.s. Insulation Material and a Method for its Production
WO2022117331A1 (en) * 2020-12-02 2022-06-09 Evonik Operations Gmbh Adhesion of blowing agent-containing particles based on polyimides or polyacrylates
FR3123360A1 (fr) * 2021-05-31 2022-12-02 Neolido Technology Sa Composition ignifugeante et ses utilisations
WO2024243729A1 (en) * 2023-05-26 2024-12-05 Sika Technology Ag Intumescent composition

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KR20100075911A (ko) 2010-07-05
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WO2009037116A3 (de) 2009-05-22
PL2190939T3 (pl) 2011-10-31
AR068447A1 (es) 2009-11-18
EP2190939B1 (de) 2011-05-11
CN101802113A (zh) 2010-08-11
DK2190939T3 (da) 2011-08-22
ZA201002533B (en) 2011-06-29
BRPI0816797A2 (pt) 2015-03-24
SI2190939T1 (sl) 2011-09-30
CL2008002729A1 (es) 2009-11-27
WO2009037116A2 (de) 2009-03-26
RU2488616C2 (ru) 2013-07-27
ATE509077T1 (de) 2011-05-15
EP2190939A2 (de) 2010-06-02

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